Polaris Offroad Vehicle manual

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W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth defects or other reproductive harm. A card containing important A TV safety information should be attached to the owner ’ s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.[...]

FOREWORD Congrat ulations and t hank you from Polar is Industr ies Inc. for purchasi ng one of our al l-ter rain vehi cles (A TV’ s). Built with Ameri can engineeri ng and manuf actur- ing know-how , it is desi gned to provi de superior ri ding comfor t, enjoyment and sa fety . This manual is fur nished to ensur e that the operator i s aware of s[...]

AN A TV IS NOT A TOY AND CAN BE HAZARDOUS T O OPERA TE. An A TV handles diff erentl y fr om other vehicl es including motor cycles and ca rs. A co llisio n o r rollov er c an oc cu r quic kly, even dur ing routi ne maneu - ve rs suc h as tu rnin g an d driv ing o n hills o r ove r ob sta cle s, if yo u fail to ta ke proper pr ecautions. SEVERE INJU[...]

• Always foll ow proper procedures for cl imbing h ills as des crib ed in this m anual. Che ck th e terra in ca refu lly be fore y ou sta rt up an y hill. Nev er clim b hills w ith ex - cessively sli ppery or loose surfaces. Shift your weight f orward. Never open the thr ottle suddenly or make sudden gear changes. Never go over the top of any hil[...]

indicat es a potenti al hazard whi ch could r esult in ser ious inj ury or deat h. W ARNING Additional I mportant Informati on... Due to our concern for the saf ety of our customers and the gener al public, Pol aris hereby st rongly r ecommends and requests t hat consumer s not have install ed on a Polar is A TV any equipment which is intended t o [...]

Th e Pol ari s Pref erred Registered Owners (PRO) Family Y our Owners P rogra m As t he owner of a new Polar is vehicle, you are ent itl ed to a FREE two- year mem- bershi p in the Polar is PRO Famil y-- - the Prefer red Regist ered Owner s Family . It’ s an owners program for Polari s owners like you, people who have chosen the finest recr eatio[...]

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CONTENTS UNDERST ANDI NG WARNINGS 1-2 .......................... SAFETY WARNING AND OPERA TION DECALS 3-13 ........... DAIL Y PRE-RIDE INSPECTION 14 ........................... OPER A T IO N WARNINGS 15-33 .............................. VEHICLE IDENTIFICA T ION NUMBERS 34 ..................... CONT ROL AND P ARTS F UNCTI ONS 35-54 .................[...]

1 UNDERST ANDING W ARNINGS A TTENTI ON: This is an ADUL T VEHICLE ONL Y ; not a t oy . Operati on is prohibi ted for any- one under 18 year s of age. READ AND UNDERST AND W ARNINGS AND OWNER’S MANUAL BEFORE OPERA TION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RI DING! Read this m anual thoroughl y refer ring to t he v ari ous areas which are being dis-[...]

2 UNDERST ANDING W ARNINGS SAFETY ALERT The foll owing precaut ionary si gnal words are used throughout this manual to con - vey the fol lowing messages: This i s the safety al ert sym bol. When you see t his symbol on your machine or in thi s manual, be aler t to the pot ential for per sonal injur y . Y our safety is involved! W ARNING Indicates a[...]

3 SAFETY W ARNING AND OPERA TION DECALS NOTE: W arning decals have been pl aced on the vehicl e for your protecti on. Read and fol low the inst ructi ons on each decal careful ly . In the event any decal becomes il - legibl e or comes of f, contact your Pol aris deal er f or a r eplacement . Any safet y de- cal needing r eplacement will be pr ovide[...]

4 SAFETY W ARNING AND OPERA TION DECALS 1[...]

5 SAFETY W ARNING AND OPERA TION DECALS 2[...]

6 SAFETY W ARNING AND OPERA TION DECALS 2 25 _ W ARNING READ AND UNDERST AND WARNI NGS AND OWNER’S M ANUAL BEFORE OPERAT ION . SEVERE INJ URY OR DEATH CAN RESUL T FROM IGNO RING W ARNINGS OR IMPROPE R USE. TO REDUCE TIPOVER RISK, BE ESPECI ALL Y CAREFUL W HEN ENCOUNTERIN G OBST ACLES AND SLOPES, WHEN BRAKING O N HILLS OR DURING TURNS. KEEP FEET O[...]

7 SAFETY W ARNING AND OPERA TION DECALS 4 5 6 7 6 3[...]

8 SAFETY W ARNING AND OPERA TION DECALS ETC This vehic le is equipped wit h a Polaris Elec tronic Thr ottle Control (ETC ) to reduc e the ris k of a s tuc k or “froz en” throttle. P lease refer to your O wner ’s Manual for details . 7072724 5 W ARNING OVER- LOADIN G CAN CAUSE STEERING , TIPPIN G AND BRAKING PRO BLEMS RE- SULTING IN LOS S OF C[...]

9 SAFETY W ARNING AND OPERA TION DECALS W ARNING LOAD DIST RIBUTION W ARNINGS Correct loading of t his vehic le is nec ess ary to m ainta in proper st ab ility and operati ng char- act erist ics . Overloading or incorrec t pos it ioning of the load effect s the v ehicl es turning, st opping dist ance and s tab ilit y . Failure to f ollow l oading r[...]

10 SAFETY W ARNING AND OPERA TION DECALS W ARNING RACK LOAD WARNING S Correc t loading of this v ehicl e is nec ess ary to maintain pr oper stabilit y and operat ing charac teris tic s. Over loading or incor rect pos itioning of the load effects the v ehicles turning, s topping distanc e and s tability. Failure to follow loading requir ements c oul[...]

11 SAFETY W ARNING AND OPERA TION DECALS 8 A TTENTION D OPERATION O F T HIS VEHI CLE WIT HOU T THE F ILTER ELEMENT WI LL SEVERELY DAMAGE THE ENGINE. D CLEAN AIR FI L TER O FT EN, MOR E FRE- QUEN T CLEANI NG REQ UIR ED IN DUSTY CONDITIONS. D L i utilisat ion de c e vé hicu le so us l i élément filtre endommage sévèr ement le moteur . D Nettoyer[...]

12 SAFETY W ARNING AND OPERA TION DECALS 9 10 DO NOT ATTEMP T ENGI NE OR CLUTCH M ODIF ICATION. DOING SO CAN CAU SE IMBALANC E AND/OR EXCESSIVE EN GINE RPM. EXCESSIVE EN GINE RPM CAN CAU SE PAR T FAILURE RES UL TI NG IN POSSIBLE SEVER E INJUR Y OR DEATH. DO NOT MODIF Y ENGI NE OR CLUTCH. 9 10 BEL T - - CLUTCH GUARD C OVERS MOVING PAR TS. CONTACT WI[...]

13 SAFETY W ARNING AND OPERA TION DECALS VEHICLE LIGHTS WILL BURN OUT IF BATT ERY IS DISCONNECTED DURING VEHICLE OPERA TION . Les phares et les ampoules du véhi cule sautent si l a batterie est désaccoupl ée durant le fonctionnement du véhicul e. 7072606 CAUTION PRECAUTION ALL WHEEL DRIVE SWITCH Do not push switc h to engage AW D if the rear wh[...]

14 DAIL Y PRE - RIDE INSPECT ION Inspect your A TV each ti me before ri ding to ensure it i s in proper worki ng or- der . If pr oper inspecti on is not done, severe injur y or death coul d result . W ARNING If a proper inspecti on is not per formed ser ious inj ury or deat h can result. Always inspect your A TV before ri ding fol lowing the checkl[...]

15 OPERA T ION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Operat ing this A TV without proper i nstruct ion. WHA T C AN HAPPEN The ri sk of an accident i s greatl y increased if the operator does not know how to oper ate the A TV properl y in dif ferent sit uations and on dif- fer ent types of terrai n. HOW TO A VOID THE HAZARD Beginning and i ne[...]

16 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Carr ying a passenger on thi s A TV . WHA T C AN HAPPEN Great ly reduces your abili ty to bal ance and control this A TV . Could cause an accident , resul ting i n harm to you and/or your passenger . HOW TO A VOID THE HAZARD Never car ry a passenger . The long seat i s to allow t he oper ator t o s[...]

17 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Operat ing thi s A TV on paved surf aces. WHA T CAN HAPPEN The A TV’ s tires are desi gned for of f- road use only; not for use on pavement. Paved surf aces may seriousl y aff ect handli ng and control of t he A TV , and may cause the vehi cle to go out of contr ol. HOW TO A VOID THE HAZARD Never[...]

18 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Operat ing thi s A TV on publi c street s, roads or highways. WHA T C AN HAPPEN Y ou can collide w ith another vehicle. HOW TO A VOID THE HAZARD Never operate thi s A TV on any public st reet, r oad or highway , even a dirt or gr avel one. In many st ates it is il legal t o operate A TVs on public [...]

19 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Operat ing thi s A TV without weari ng an approved helmet , eye pr otecti on and prot ective clot hing. WHA T C AN HAPPEN Operat ing without an approved hel met incr eases your chances of a se- vere head i njury or deat h in the event of an accident. Operat ing wit hout eye protect ion can result i[...]

20 OPERA T ION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Operat ing this A TV after consumi ng alcohol or drugs. WHA T C AN HAPPEN Could seriousl y affect your j udgment. Could cause you to r eact more sl owly . Could af fect your balance and per ception. Could r esult in an acci dent. HOW TO A VOID THE HAZARD Never consume al cohol or dr ugs be[...]

21 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Att empting wheel ies, jum ps and other st unts. WHA T CAN HAPPEN Incr eases the chance of an accident , incl uding an overt urn. HOW TO A VOID THE HAZARD Never at tempt st unts, such as wheel ies or j umps. Don’t tr y to show of f.[...]

22 OPERA T ION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Failur e to inspect the A TV before operat ing. Failur e to proper ly maint ain the A TV . WHA T C AN HAPPEN Incr eases the possibili ty of an accident or equipment damage. HOW TO A VOID THE HAZARD Always inspect your A TV each time you use it to m ake sure t he A TV is in saf e operati ng[...]

23 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Failur e to use extr a care when operating this A TV on unfam iliar te rrain . WHA T C AN HAPPEN Y ou can come upon hidden rocks, bumps, or holes, wit hout enough time to rea ct. Could r esult in t he A TV overturni ng or going out of control . HOW TO A VOID THE HAZARD Go slowl y and be extra caref[...]

24 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Failu re to use ext ra care when operati ng on excessively rough, sl ip- pery or loose terr ain. WHA T C AN HAPPEN Could cause loss of t racti on or vehicle contr ol, which could resul t in an accident , includi ng an overtur n. HOW TO A VOID THE HAZARD Do not oper ate on excessively r ough, slippe[...]

25 OPERA T ION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Tur ning impr operly . WHA T C AN HAPPEN A TV co uld g o ou t of con trol, cau sin g a co llisio n or ov ertu rn. HOW TO A VOID THE HAZARD Always fol low proper procedures f or tur ning as described i n the Own- er’ s Manual. See page 63 . Pract ice tur ning at low speeds befor e attempt[...]

26 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Climb ing h ills impr operly . WHA T C AN HAPPEN Could cause loss of control or cause A TV to overt urn. HOW TO A VOID THE HAZARD Always f ollow pr oper procedur es for cli mbing hi lls as descri bed in the Owner’ s Manual. See pages 65 thr ough 68. Alwa ys c he ck th e terra in ca refu lly be fo[...]

27 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Going down a hi ll impr operly . WHA T C AN HAPPEN Could cause loss of control or cause A TV to overt urn. HOW TO A VOID THE HAZARD Always fol low proper procedur es for going down h ills as d es cribe d in the Owner’ s Manual. See page 67. NOTE: A special technique is requi red when braki ng as [...]

28 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Impr operly cr ossing hil ls or tur ning on hil ls. WHA T C AN HAPPEN Could cause loss of control or cause A TV to overt urn. HOW TO A VOID THE HAZARD Never at tempt t o turn t he A TV around on any hi ll unt il you have mas- ter ed the tur ning technique as descri bed in t he Owner’ s Manual on [...]

29 OPERA T ION W ARNINGS W ARNING POTENTIAL HAZARD Stallin g, ro lling b ack wa rds or im pr operly dismount ing while cl imbing a h ill. WHA T CAN HAPPEN Could r esult in A TV overturni ng. HOW TO A VOID THE HAZARD Maint ain steady speed when cli mbing a hil l. I fy o ul o s ea l lf o r w a r d speed: Keep weight uphill . Apply the br akes. Lock p[...]

30 OPERA T ION W ARNINGS W ARNING W ARNING W ARNING POTENTIAL HAZARD Impr operly operat ing over obstacles. WHA T C AN HAPPEN Could cause loss of control or a collisi on. Could cause the A TV to overt urn. HOW TO A VOID THE HAZARD Befor e operati ng in a new area, check for obst acles. Use extr eme caution when r iding over lar ge obsta cles, such [...]

31 OPERA T ION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Operat ing thi s A TV thr ough deep or fast flowi ng water . WHA T CAN HAPPEN Ti res may float, causi ng loss of tract ion and loss of cont rol, which could lead t o an accident. HOW TO A VOID THE HAZARD Never operat e this A TV in fast flowi ng water or in wat er deeper than that specifi [...]

32 OPERA T ION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Operat ing this A TV with impr oper ti res, or with impr oper or uneven ti re pressur e. WHA T C AN HAPPEN Use of im proper t ires on thi s A TV , or oper ation of thi s A TV with impr op- er or uneven tir e pressure, may cause loss of control, and incr eases the r isk of an accident . HOW[...]

33 OPERA T ION W ARNINGS W ARNING W ARNING POTENTIAL HAZARD Overl oading this A TV or carryi ng or towi ng cargo impr operly . WHA T C AN HAPPEN Could cause changes in vehi cle handli ng which could l ead to an ac- cident . HOW TO A VOID THE HAZARD Never exceed t he stated load capaci ty for this A TV . Cargo should be p roperly di stri buted and s[...]

34 VEHICLE IDENTIF ICA TION NUM BERS 2O nr e c o i l housing 1 VIN on the l ower lef t side of the fr ame tube Impor tant: Recor d these numbers f rom your A TV in the spaces provi ded. 1. Frame VI N 2. Engine Seri al Number (Right f ront side of engine crankcase) Remove the spar e key and store i n a safe place. Record your igni tion key num- ber [...]

35 CONTROL AND P ART S FUNCTIONS Engin e Electrical Switches 1. Over ride Swi tch (Rever se Speed Limiter ) - This vehicle i s equipped wit h a re- verse speed limi ter syst em. T o obtain addit ional power whil e backing up, depress the over ride butt on. W ARNING: Never act ivate t he overri de button while t hrott le is open as l oss of contr ol[...]

36 CONTROL AND P ART S FUNCTIONS Light Swi tches and Indi cator Li ghts Swit ches Each Polar is A TV has a main switch. It i s locat ed on the r ight hand side of the ma- chine and oper ated with a key . The light swit ch is located on the left hand handl ebar . In addition t o turning t he light s on and of f, it also swit ches the li ghts fr om H[...]

37 CONTROL AND P ART S FUNCTIONS Wit h engine runni ng, veri fy functi on of indi cator l ights each ti me A TV is used. WARNING This A TV is not equipped wi th highway approved light ing. This A TV is designed for off -road use onl y and must not be r idden on str eets or hi ghways. Use cauti on and dri ve at reduced speeds in condi tions of reduc[...]

38 CONTROL AND P ART S FUNCTIONS Engine Throttle a nd Choke Throt tle Lever Engine speed and vehicle movem ent are cont rolled by pr essing the t hrott le le- ver . The thr ottle l ever is spr ing loaded and engine speed r eturns to i dle when the lever is r eleased. This vehicle is equipped wit h a Polari s Electr onic Throt tle Contr ol (ETC) whi[...]

39 CONTROL AND P ART S FUNCTIONS Thro ttle Co ntrol/B rakes Th rottl e Con tro l L ever Sto p The thr ottle cont rol l ever i ncorporat es an adjust able stop. This can be ad- just ed to lim it the am ount of throt tle opening by looseni ng the screw ( A) and slid ing the stop t o a desired set ting. Then ti ghten screw . Fro nt an d Rear Brakes Th[...]

40 CONTROL AND P ART S FUNCTIONS Parking Brake Setti ng th e Parkin g Brake 1. Squeeze the lef t hand brake lever two or thr ee times and hol d it. 2. Rota te the p ark bra ke lo ck in to the notches on t he master cyl inder body . Release t he brake lever . 3. T o rel ease the parki ng brake l ock, squeeze the br ake lever . It wi ll ret urn to i [...]

41 CONTROL AND P ART S FUNCTIONS Auxiliary M echanical Brake Y our Po laris A TV h as a n au xiliary m ec hanical brake pr ovided as a safet y featur e. It is locat ed on the i nside of the right fl oor board and is operat ed by the r ight foot. It is i ntended as a backup to the hydraul ic brake system, especial ly if the hydr aulic system becomes[...]

42 CONTROL AND P ART S FUNCTIONS T ransmission Gear Select or Operat ion Shif t patterns depend on the type of vehicle you own. Please check your Owner’s Manual Supplement t o define your ma- chine’ s shift patt ern. The transmi ssion gear selector i s located on the r ight side of the vehicle dir ectly above and for ward of t he engine r ecoil[...]

43 CONTROL AND P ART S FUNCTIONS Demand 4 Drive (Found on models with All Wheel Dr ive) AWD Butto n AWD Butto n Out “Of f” AWD Butto n in “On” AW D Indicator Light Exclu sive Deman d 4 Dri ve System (Al l W heel Drive) This Polar is A WD is equipped wi th a unique, Pol aris excl usive, Demand 4 Dr ive (A WD) syst em which is activat ed by a[...]

44 CONTROL AND P ART S FUNCTIONS Dise ngaging Whee l Hubs When backing uphi ll whil e in Demand 4 Dr ive and then going forwar d downhill , one or bot h hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stoppi ng, shif ting t o and moving in r everse. Then proceed i n for ward again. Y ou can tell i f only one f [...]

45 CONTROL AND P ART S FUNCTIONS Engine Cool ing Sy stem Coo lant Level The recover y bottle, located on the lef t side of the machine, must be maint ained between the minimum and maximum levels indi cated on the recover y bottl e. The engine coolant level is contr olled or mai ntained by t he recovery sys- tem. The recover y system compo- nents ar[...]

46 CONTROL AND P ART S FUNCTIONS Engine Cool ing Sy stem Radiat or Coolant Level Inspecti on NOTE: This pr ocedure is only re- quir ed if the cool ing syst em has been drai ned for m aintenance and/or re- pair . However , if t he recovery bottl e has run dr y , the level in the radiat or should be inspected and coolant added if necessary . W ARNING[...]

47 CONTROL AND P ART S FUNCTIONS Engine Cool ing Sy stem T o ins ure th at the c oo lan t mainta ins its a bility to p rote ct the engine, i t is recom - mended that the system be compl etely dr ained ever y two year s and a f resh mi xture of ant ifreeze and wat er be added. Polaris recomm ends the use of Polar is Pre- mium 60/ 40 anti- freeze/ co[...]

48 CONTROL AND P ART S FUNCTIONS Engine Fue l and Oil Sy stem 1 2 The fuel tank fill er cap (1) is located di rectl y behind the handlebar . Ref er to your owner’ s Manual Supplement for tank capaci ty . Use eit her leaded or unleaded gas- oline w ith a mi nimum pump octane num ber of 87 R+ M/ 2 octane. On models wi th a two cycl e engine, t he e[...]

49 CONTROL AND P ART S FUNCTIONS Engine Fue l Safety /Fuel/ Filter The Polar is A TV is equipped wit h a unique in- line fuel filt er . This fil ter should be replaced by your dealer aft er every 100 hours of operat ion or annually . Do not attem pt to clean t he fuel f ilt er . W ARNING Gasoli ne is highly f lammabl e and explosive under cer tain [...]

50 CONTROL AND P ART S FUNCTIONS 4 Cycle Pre mium 4 Synthe tic Lubricant Polar is Premi um 4 All Season Synt hetic engine oi l has been special ly f ormulat ed for use in Polari s 4 cycle engines. It i s a full y syntheti c, high perfor mance, mul ti- vis- cosit y oil designed t o provide t he ulti mate in l ubricati on perfor mance and prot ec- ti[...]

51 CONTROL AND P ART S FUNCTIONS Oil and Filter C hange (Co nt.) 4. Place a dr ain pan beneath t he oil tank and remove the drai n plug. CAUTION: Oil may be hot. Do not al low hot oi l to come i nto contact with ski n as serious burns may r esult. 5. All ow oil t o drain compl etely . 6. Inst all a new seal ing washer ( PN 5850135) on oil dr ain pl[...]

52 CONTROL AND P ART S FUNCTIONS Polar is 2 - Cycle Lubr icants Polar is has a fami ly of pr emium oil s availabl e for use i n all our product s and highl y recommends t heir use. The only oils recomm ended for Polar is 2-cycle A TVs are Polar is Premi um 2-cycle oi l or Premi um Gold Synt hetic 2- cycle oil. CAUTI ON: Engin e warran ty co verage [...]

53 CONTROL AND P ART S FUNCTIONS Recoil St arter Recoil Star ter If the batt ery is weak and cannot st art t he engine, use of t he recoil star ter l ocated on the r ight side of the machi ne will al low vehicl e operati on until repairs can be made. Polar is engines are equi pped with aut omatic decom pressors. Thi s makes recoi l star ting possib[...]

54 CONTROL AND P ART S FUNCTIONS Drai n the recoil housing aft er operat ing the A TV in ver y wet condi tions. This should also be done bef ore stori ng the A TV . The drain screw is l ocated at the bottom of the r ecoil housing. Remove the screw wi th a 10mm wrench. Reinst all scr ew once housing has been drai ned. CAUTION: Make sure t he manual [...]

55 ST ARTING THE ENGINE Proce dure for Sta rting a Cold E ngine 1. Place the t ransmissi on in neutr al and push the vehi cle to a l evel surface. 2. Lock the parki ng brake. 3. Tur n the fuel t ank valve to ON. 4. Sit on t he vehicle. “HAL F” “FULL” “OFF” Choke Lever Side View 5. Move the choke lever to the FULL posit ion. 6. Tur n the[...]

56 VEHICLE BREAK - IN PERI OD 2 Cycle E ngines The break i n period f or your new Polar is A TV is def ined as t he t ime it takes to use the f irst t ank of gasoli ne. No single action on your par t is as important as a proper break in period. Careful t reatment of a new engine will result in more eff icient per - for mance and longer l ife for th[...]

57 VEHICLE BREAK - IN PERI OD 4 Cycle E ngines The break in peri od for your new Polari s A TV is defined as the fir st ten hours of op- erat ion, or t he time i t takes t o use the fi rst t wo tanks full of gasoli ne. No single act ion on your par t is as i mportant as a proper break i n peri od. Careful t reatment of a new engine wil l resul t in[...]

58 RIDING GEAR Safe Ri ding Ge ar Always wear cl othing sui ted to t he type of r iding you are doing. A TV ridi ng requi res special prot ective cloth ing which will make you feel more comf ortable and reduce chances of injury . 1. Helmet Y our helmet is the most im portant piece of prot ective gear for safe ridi ng. A hel- met can pr event a seri[...]

59 CARR YING LOADS Y our A TV has been designed to carry a cert ain amount of load. CARGO WEIGHT should be evenly di stri buted (1/ 3 on the fr ont and 2/3 on t he rear) and mounted as low as possi ble. When operat ing over r ough or hil ly ter rain, reduce speed and car - go to mai ntain st able drivi ng conditi ons. Never exceed the f ollowi ng w[...]

60 CARGO WEIGHT DISTRIBUTION 2/3 of Load on Rear Rack 1/3 of Load on Front Rack W A RNING Corr ect loading of this vehi cle is necessary t o maintai n proper st abili ty and operat ing characte risti cs. Overloadi ng or incor rect positi oning of the load af- fect s the vehicle’ s turning, stopping di stance and stab ility . Failu re to fo llow l[...]

61 DAIL Y PRE - RIDE INSPECT ION Inspect your A TV each ti me before ri ding to ensure it i s in proper worki ng or- der . If pr oper inspect ion is not done, severe injur y or death coul d result . W ARNING If a proper inspecti on is not per formed ser ious inj ury or deat h can result. Always inspect your A TV before ri ding fol lowing the checkl[...]

62 RIDING 1. Sit upr ight wi th both feet on the footr ests and both hands on t he handlebars. 2. After start ing the engi ne and allowing i t to war m up, shif t the tr ansmission into gear . 3. Check your surr oundings and deter mine your pat h of tr avel. 4. Release the par king brake. 5. Slowly depr ess the thr ottle w ith your r ight t humb an[...]

63 RIDING Making T urns Practi ce making tu rns at sl ow speed s. Polari s A TVs are equipped wit h a solid rear axle which dr ives both rear wheel s equally at all t imes. This means that t he wheel on the out side of the tur n must travel a great er dist ance than the insi de wheel when turning and t he inside tire m ust sl ip tr action sli ghtly[...]

64 RIDING Ridin g On Slippery Surfaces Wh enever ridi ng o n sli pp ery surfaces such as w et trail s or lo ose gravel , or duri ng co ld f reezin g weat her , sp ecial att enti on mu st be pai d to preven t vehicl e turn over. Alw ays: 1. Slow down when enter ing sli ppery areas. 2. Mainta in a hi gh level of alert ness, r eading the trai l and av[...]

65 RIDING T raveling Uph ill 25 _ Maximum Wh enever traveli ng u ph il l alw ays travel straigh t uphill and: 1. Avoi d steep hill s. 2. Keep both feet on the footr ests. 3. Tr ansfer your weight for ward. 4. Proceed at a st eady rate of speed and thr ottle openi ng. 5. Remain aler t and be prepar ed to take em ergency action. This may include quic[...]

66 RIDING Sidehilling Sidehilling your A TV is one of the most dangerous t ypes of riding and s hould be avoide d if poss ible. In t he event you d o enter i nto a situa tion where side hilling is n ecessary , alw ays: 1. Slow down. 2. Lean into the hil l transf erri ng your upper body weight t oward the hill whi le keep- ing your feet on t he foot[...]

67 RIDING T raveling Down hill Wh enever descen di ng a h ill, alw ays: 1. Drive d irec tly do wn hill. 2. Tr ansfer your weight to the rear of t he vehicle. 3. Slow down. 4. Apply the br akes slightl y to aid i n slowing. Fam iliariz e yo urs elf with the a ux iliary re ar bra ke pedal and i ts use i n the event loss of normal ser vice brakes occu[...]

68 RIDING T urning Around On A Hill 8’ Uphill If the A TV stalls while c limbing a hill, n ever b ack i t d ow n th e h ill! One maneu ver which can b e u sed wh en i t is n ecessary to tu rn ar ound while clim bing a hill is the K- turn. 1. Stop and lock t he parking br ake while mai ntaining body wei ght uph ill. 2. Leave transm ission in f orw[...]

69 RIDING Crossin g Streams Y our Polar is A TV can oper ate through wate r up to dept hs r eaching the f oot rests. Before ford in g streams al ways: 1. Determi ne water dept hs and current . 2. Choose a crossing wher e both banks have gradual incl ines. 3. Proceed slowl y , avoiding r ocks and obstacles if possible. 4. After crossing, dry the bra[...]

70 RIDING T rail Obstacles Keep Alert! Look ahead and learn t o read the t rail as you ri de. Stay on the r ight side of the t rail, if possible, and be const antly aler t for hazar ds such as logs, rocks and low hanging branches. W ARNING Hidden or unseen hazards on the t rail can be dangerous. Personal i njury or the vehi cle overt urning can occ[...]

71 RIDING Backing U p Backin g Up 1. Whenever backi ng up, always avoid backi ng downhill . 2. Back slowly . 3. When in r everse, apply t he brakes li ghtly for stopping. 4. Avoi d turning at sharp angles in r everse. 5. Never open the t hrott le suddenly whi le backing. 6. Never acti vate overr ide butt on while t hrott le is open. Loss of control[...]

72 RIDING P a r k i n go na nI n c l i n e Wh enever th e V eh icl e is Parked 1. Tur n the engine of f. 2. Place the t ransmissi on in gear . 3. Set the par king brake. 4. Avoi d parking on an incl ine. If it is necessary to park on an incline, always bl ock the r ear wheels on the down hi ll si de as shown above. 5. Shut of f fuel supply . indica[...]

73 BA TTER Y Batte ry CAUTION Whenever rem oving the batt ery , discon- nect t he negative (bl ack) cable fi rst. When rei nstalli ng the batt ery , connect the nega- ti ve (black) cable l ast. Reple nishing the Batte ry Fluid A poorl y maintai ned battery wi ll deteri orate rapi dly . Check the batter y flui d level oft en. The flui d level shoul [...]

74 BA TTER Y Batte ry Remo val 1. Disconnect hold down s tr aps holding the electr ical box and batter y in positi on and remove bat tery cover . 2. Remove the batt ery vent t ube from t he batter y . 3. Disconnect t he black (negat ive) batt ery cable f irst . 4. Disconnect t he red (posi tive) batter y cable next. 5. Lift t he battery out of the [...]

75 NOISE EMI SSION CONT ROL SYSTEM REGUL A TION T AMPERING WITH NOISE CONTROL SYSTEM PROHIBI TED! U.S. Federal l aw prohibi ts the f ollowing act s or the causing t hereof: (1) The removal or r endering inoper ative by any person other t han for purposes of maint enance, repair , or replacem ent of any device or element of design i ncorpo- rat ed i[...]

76 MAINTENANCE Spark A rrestor The exhaust pi pe must be peri odically purged of accumul ated carbon as foll ows: 1. Remove the clean out plugs locat ed on the bott om of the muf fl er as shown above. 2. Place the tr ansmission i n neutr al and start the en- gine. Purge accumul ated carbon from t he system by momentar ily r evving the engine severa[...]

77 MAINTENANCE Spark Arr estor (C ont.) W ARNING D Do not per form t his operat ion immedi ately aft er the engi ne has been run because the exhaust system becomes ver y hot. D Because of t he increased f ire hazar d, make sure t hat ther e are no com- busti ble mater ials in t he area when purgi ng the spark ar restor . D W ear eye protect ion. D [...]

78 MAINTENANCE T ool Kits T o help you perfor m routi ne maintenance, a t ool kit is provided i n the stor age compart ment under t he seat. It ems included i n the kit s are: 2 cycle engin es D fl at screwdri ver D spa rk plu g wre nch w ith Ph illips head screwdriver D wrench D ti re pressur e gauge D spanner wr ench for adj usting r ear shock sp[...]

79 MAINTENANCE Periodi c Maintena nce Sc hedule Caref ul periodi c maintenance w ill hel p keep your vehi cle i n the safest, m ost r eliable condit ion. I nspection, adjust ment and lubr icati on int ervals of important com po- nents are expl ained in t he foll owing chart Maint enance inter vals are based upon aver age riding condi tions and a ve[...]

80 MAINTENANCE Periodi c Maintena nce Sc hedule (Cont.) Item Hours or Odometer Frequency Remarks J L Fuel System 100 hours 12 months Check for leaks at tank c ap, lines, fuel valve, fi lter, pump and carbur etor. Re- place li nes every two years. J Fuel Filter 100 hrs 12 months Replace annual ly Carburetor Float Bowl 50 hrs 6 months Drain bowl peri[...]

81 MAINTENANCE Periodi c Maintena nce Sc hedule (Cont.) Item Hours or Odometer Frequency Remarks Headlamp Inspection Daily D aily Check operation daily ; apply Polaris di- electric grease to c onnector when re- placed T ail lamp inspe ction Daily Daily Check operation daily; apply Polaris di- electric grease to s ocket when replaced Bra ke System P[...]

82 MAINTENANCE Lubrication Re commenda tions Item Lube Rec. Method Frequency* 1. Engine Oil (2-Cycle) Polari s Injection O il Fill oil tank. See page 48. As needed, when refueling 2.Engine OI l (4-Cycle) Polari s Pre- mium 4 Sy n- thetic 0W40 Add to proper lev el on dips tick . See page 50. Chec k lev el dai- ly. 3. Brak e Fluid DOT 3 Only Maintain[...]

83 MAINTENANCE Lubrication Re commenda tions 14. Front A Ar m Pivot S haft Greas e** ∆ Loc ate fitting on piv ot s haft and grease w ith greas e gun. Every 3 months or 50 hours 15. Counter Bal- ance H ousing (400) SAE 10/30 Check lev el on dips tick and add oil as neces sar y. Change annually. T o change oil s ee page 1 17. Chec k month- ly and c[...]

84 MAINTENANCE Lubrication Re commenda tions Operat ing Range Full 4. Tr ansmission 7. Front Pr op Shaft (U-J oin t) 12. Axle Cardan Front Dr ive (A WD Models) 6. Rear Halfshaf t (U Jo int) 8. Propshaf t Y oke 9. Speedo meter Cabl e Fill pl ug 5. Front Gear Case 15. Counter balance Dipsti ck[...]

85 MAINTENANCE Lubrication Re commenda tions 4WD 17. Steer ing Post Bushings 25. T ie Rod End 25. T ie Rod End 13. Ball J oin t 14. Front A- Arm Pivot Shaf t Lower Upper 11 . 4 O’clock pos ition 1 1. Demand 4 Hubs 17. Steer ing Post Bushings 25. T ie Rod Ends 13. Ball J oin t 14. Front A- Arm Pivot Shaf t Lower Upper Tr a i l B o s s[...]

86 MAINTENANCE Lubrication Re commenda tions 17. Steer ing Post Bushings 13. Ball Joi nt 14. Front A- Arm Pivot Shaf t Lower Upper 25. T ie Rod End 13. Ball Joi nt 14. Front A- Arm Pivot Shaf t 11 . 4 O’clock pos ition 1 1. Demand 4 Hubs[...]

87 MAINTENANCE Lubrication Re commenda tions 19. Swing Arm Bushings 18. Rear Axle Bearing Forward 16. Output shaf t sup- port bearing gr ease fit - ting 20. Center and Front Eccent rics 21. Upper Contr ol Arm 23. Rear Wheel H u bB e a r i n gC a r r i - er 24. Rear Anti- Roll Bar 22. Lower Contr ol Arm INDEPEN DENT REAR SU SPENSION[...]

88 MAINTENANCE Period ic Mainten ance Recor d Use the f ollowing char t to r ecord peri odic maint enance work: Maint enance Int erval Perf ormed Se rvic ing Date Se rvic ing Dealer or Person Remarks First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.[...]

89 MAINTENANCE Steering Hand lebar Adju stment Y our A TV has handlebars whi ch can be adjusted for your per sonal fit. 1. Locate handlebar bolt s. On mod- els with a headlight pod, i t will be necessary t o remove the upper headlight pod. On other models remove t he handlebar cover . 2. Loosen the four bolts. 3. Adjust handlebar to desir ed height[...]

90 MAINTENANCE The fol lowing it ems should b e checked occasional ly for tightness; or i f they have been loosened f or maint enance service. Axle an d Wh eel Nu t T o rqu e Speci ficat io ns Model Item Specifi cation Front Spi ndle Nut(s) 40 Ft. Lbs. 2 X 4 Front Wheel Nut s 15 Ft. Lbs. 2 X 4 Rear Axle Nut(s) 80 Ft. Lbs. Rear Wheel Nuts 50 Ft. Lbs[...]

91 MAINTENANCE Rear Spri ng Adj ustmen t The rear shock absorber spri ng is adjust ed by rot ating the adjust er i n the di recti on requi red to incr ease or decr ease spring tensi on. Rear Spring Adjust ment Rear Spring Adjust ment Cam[...]

92 MAINTENANCE Optional S uspens ion Springs Although your Polari s A TV suspension has the capab ility of p rov idin g yo u with th e best r ide possible, the fol lowing accessor y spri ngs are avai lable t o bett er suit your indivi dual ridi ng preference. NOTE: Opti onal spri ngs may be a diff erent color than standard spr ings. Owner may paint[...]

93 MAINTENANCE SOFT FIRM Xpress 300 - Rear Com pre ssio n Spring 7041518-067 OPTION 1 75 lb/ in 7041204-157 ST ANDARD 190 l b/in 7041303-067 OPTION 2 50 lb/ in Xpress 300 - Front Str ut Spring 7041238-067 OPTION 6 1 lb/i n 7041375-157 ST ANDARD 64/1 13 lb/in 7041450-067 OPTION 1 01 lb/ in Magnum 4x4 -- Front Str ut Spring 7041238-067 OPTION 6 1 lb/[...]

94 MAINTENANCE Side P anel Re mova l (Gen IV Mode ls) Side panel r emoval may be di ff icult until t he locking t abs and receivers have been snapped and unsnapped a few t imes. 1. Remove seat . Grasp rear of si de panel near rear cab. Wit h a quick and firm moti on, pull the panel for ward and outward to disengage the t wo r ear tabs. 2. Place han[...]

95 MAINTENANCE Air C leaner T rail Boss, Xp ress 300, Xplorer 300, Xp lorer 400 Dual Stage Ai r Clean er The Polar is A TV is equipped wi th a dual st age engine air f ilt rati on system . The pri mary pre-cleaner f oam boot is designed t o remove th e majori ty of dust par ticles bef ore they reach t he secondary dr y filt er elem ent. Primary P r[...]

96 MAINTENANCE Air C leaner T rail Blazer , T rail Bo ss, Xpress 300, Xplorer 300, Xp lorer 400 Sec ondary (M ain) Filter Inspect the secondar y filt er weekly or after every 50 hour s of operat ion. CAUTION: Never operat e the A TV wit h the fil ter element r emoved. Dirt will enter the engi ne causing serious r apid wear and damage t o the engine[...]

97 MAINTENANCE Air Filt er Service Magnum 2 x 4, Magnum 4 x 4 It i s recommended that t he air fi lter be inspect ed weekly and r eplaced i f dir ty . When ridi ng in ext remely dusty condi tions repl acement wil l be requi red more of ten. 1. Lift up on the rear of the seat. 2. Pull t he seat back and fr ee of t he tabs. NOTE: When re ins tallin g[...]

98 MAINTENANCE Primary Pre - Filter Service Magnum 2 x4 a nd 4x 4 The pre f ilter should be cleaned befor e each ride, using t he followi ng procedure. 1. Remove pr e-fi lter element . Note posit ion of duct suppor t wir e. It must be properl y posi- ti oned before reinst alli ng pre- filter . 2. Clean the el ement wit h high flash point solvent , [...]

99 MAINTENANCE Air Filt er Service Sport, Scrambler 400 1. Release seat l atch and lif t up on the r ear of t he seat. 2. Pull t he seat back and fr ee the tab fr om front cab. 3. Remove the two wi ng nuts and washers securi ng the air fi lter access cover . 4. Remove the cover . Inspect t he gasket. It should adhere ti ghtly to t he cover and seal[...]

100 MAINTENANCE Air Filt er Service T rail Blazer 1. Release seat l atch and lif t up on the r ear of t he seat. 2. Pull t he seat back and fr ee of the t abs. 3. Remov e the p rimary air filt er box. 4. Remove the yell ow pre-cl eaner foam boot , held i n place by a gray collar , from t he air box. Do not r emove the coll ar . 5. Careful ly wash t[...]

101 MAINTENANCE Air Filt er Service Scrambler 500 1. Remove seat. 2. Release cli ps and remove cov- er . 3. Loosen clamp and r emove fi lter 4. Remove fabr ic type pre- fil ter fr om main fi lter . Wash p re-f ilter in soapy water and dry it. 5. Reinstal l pre-fi lter i n main fil ter . Replace mai n filt er as requir ed. Air Filt er Service Sport [...]

102 MAINTENANCE CAUTION: Oper ation of your A TV without a br eather fil ter can cause engine dam - age. Breat her Filter an d Hoses Scrambl er 500 W ARNING: Do not perfor m this operati on immediat ely after t he engine has been run. The exhaust system becomes ver y hot and can cause severe burns. 1. Remove heat shield scr ews and front fender to [...]

103 MAINTENANCE Breat her Filter and H ose Sport sman 500, Xplorer 500 1. Remove seat and air box lid. 2. Locate foam breather f ilt er which is i n the fr ont lef t corner of air box covering the engine breat her hose fit ting hol e on the fr ont inside of the air box. 3. Pull f ilt er out and blow off wit h compressed air . If f ilt er still has [...]

104 MAINTENANCE Steering I nspection The steer ing assembly of the machine should be checked periodical ly for l oose nuts and bolt s. If l oose nuts and bolt s are found, have your dealer ti ghten t hem befor e riding your vehicle. Camber an d Caster The camber and cast er are non- adjustabl e. T oe Alignment Y ou can check the toe align- ment of [...]

105 MAINTENANCE Front Brake The fr ont brakes ar e hydrauli c disc type br akes which ar e activat ed by the brake lever being moved toward t he handlebar . These brakes are sel f-adj usting and re- quir e no adjustment . The fol lowing checks are recomm ended to keep the brake system i n good operat- ing conditi on. How often they need checking de[...]

106 MAINTENANCE Rear and A uxiliary Mechanical Brake Rear Brake The rear brake is a hydraulic disc type br ake which is act ivated by the same lever which acti vates the front brake syst em. The rear brake sys- tem i s self adjust ing and requi res no maint enance other than periodi c checks of t he pads for wear . We ar Line D Pads should be chang[...]

107 MAINTENANCE Auxiliary B rake Adjustmen t (Co nt.) Pola ris A TV s ha ve two d ifferent typ es o f au xilia ry bra ke a djus tme nt. Co ns ult yo ur owner’ s manual supplement to determ ine what type your machine has and adjust accordi ngly . 1. Ty p e I : I f adjustment is neces- sary tur n adjuster bolt (A) clock- wise unt il disc rot ation [...]

108 MAINTENANCE Oil Pump Adjus tment P roce dure 40 0 Engines 1. Before adj usting t he oil pump, check engine idle RPM and carburet or ad- just ments which ar e found in t he own- er’ s manual supplement. 2. Remove electroni c throt tle contr ol (ETC) cover . 3. Loosen throt tle cabl e jam nut and t urn adjust er in or out until ther e is 1/16 ?[...]

109 MAINTENANCE Oil Pump Adjus tment P roce dure 250 and 300 Eng in es 1. Before adj usting t he oil pump, check engine idl e RPM and car- buret or adjustment s which are found in t he owner’s manual sup- plement . 2. Remove electr onic thr ottl e con- tr ol (ETC) cover . 3. Loosen throt tle cabl e jam nut and tur n adjuster i n or out unt il t h[...]

11 0 MAINTENANCE Oil Pump Bleeding Pro cedure 1. Fill th e o il res erv oir with Po laris injec tor o il. 2. Loosening the bl eeder screw i s only necessary when the oil supply line has been disconnect ed from t he pump or the oi l reser voir and suppl y line have been complet ely run out of oil . In these cases, loosen the pum p bleed scr ew one f[...]

111 MAINTENANCE Engine Chok e Adjustm ent 2 Cy cle Engines Wit h the dash mounted choke cont rol t oggle fl ipped to ful l of f posit ion, the choke plunger must be seat ed on the fuel passageway i n the carbur etor . If t he plunger is not seat ed on the passageway , the engi ne will f lood or r un too ri ch, causing spark plug f ouling and very p[...]

11 2 MAINTENANCE Carburetor/E ngine Idle RP M Adjustment 2 Cycle E ngines If the engine i dle speed is not satisfact ory , and al l other conditi ons are f avorable, the car buretor can be adj usted as fol lows: 1. War m up t he engine by running the vehicl e approximatel y five minut es. 2. Place the t ransmissi on in gear with t he parking br ake[...]

11 3 MAINTENANCE Carburetor/E ngine Idle RP M Adjustment 4-cycle Eng ines If the engine i dle speed is not sat is- fact ory , and all ot her conditions are favor able, the carbur etor can be ad- just ed as follows: 1. War m up the engine by r unning the vehicl e approxim ately five minut es. 2. Place the t ransmissi on in gear with t he parking br [...]

11 4 MAINTENANCE Spark P lugs Check your owner’ s manual supplem ent for r ecommended spark pl ug and gap. The spark plug and i ts condit ion i s indicati ve of engine oper ation. The spark plug fi ring end condit ion should be r ead after the engine i s warmed up and the vehi cle is dr iven at higher speeds. Immediat ely check the spar k plug fo[...]

11 5 MAINTENANCE T rans miss ion Lubrica tion Tr ansmission Di pstick The tr ansmission di pstick is l ocated on the r ight si de of the machi ne. The tr ansmission l ubricant l evel should be checked monthl y or 1000 miles (1600 km), whichever comes fi rst. Transmi ssion oil should be changed annuall y . Wit h the A TV on a level surface, remove f[...]

11 6 MAINTENANCE Fron t Gearcase Lubric ation Sport 500, Xplorer 500, Scrambler 400 Fill pl ug Fro nt G earcase Lubrica tion The fr ont gearcase f ill pl ug is locat ed on the ri ght side of t he machine. The fr ont gearcase l ubricant l evel should be checked every six months or 1000 mil es (1600 km), whichever comes fi rst. Front gearcase oil sho[...]

11 7 MAINTENANCE Counter Bal ance Lubri cation 400 E ngines The counter balance oil should be checked semi- annually and oil should be added or changed as necessary . The oil should be changed annually , especiall y be- for e off season storage. If the ma- chine is used i n wet conditions the oil shoul d be checked more fre - quently . If the oi l [...]

11 8 MAINTENANCE Wh eel Removal Fr ont or Rear Wh eel Removal Pro cedu re 1. Stop the engi ne, place t he transmi ssion in gear and lock the par king brake. 2. Loosen the wheel nut s slight ly . 3. Elevate t he side of t he vehicle by placi ng a suitabl e stand under the f ootrest fr ame as shown. 4. Remove the wheel nuts and rem ove the wheel. Wh [...]

11 9 MAINTENANCE T ire Inspectio n CAUTION: Mai ntain pr oper t ire pr essure accor ding to charts bel ow . Impr oper tire inf lation may af fect A TV maneuverabili ty . When repl acing a ti re always use or iginal equipment size and t ype. CAUTION: The use of non-standar d size or t ype tir es may aff ect A TV handling. Tire Tread Depth Always rep[...]

120 MAINTENANCE Drive Chain In spection and A djustment Polar is A TV dri ve chains ar e equipped wi th O-r ing seal ed permanentl y greased pins and r ollers. However , i t is st ill necessar y to lubr icate the outer surf aces of t he rolle r . CAUTION: Never wash the chain wit h a high pressur e washer or gasoli ne. Dam- age to t he O-ri ngs wil[...]

121 MAINTENANCE Adjustment P rocedure (cont. ) 5. Ti ghten eccentri c clamp bolt s to 45 ft . lbs. (6 .21 kg/m). Check chain tensi on. Gen II and III Models 1. Remove cott er pin and washer connect ing brake pedal linkage to cali per actu- ati ng arm. Remove l inkage from arm. 2. Remove right front f ender mud fl ap foot boar d attachi ng hardware.[...]

122 MAINTENANCE Rear D rive Chain Slack A djustment CAUTION: Never adjust or operat e the vehi cle wit h the r ear drive chain too loose or too tight as sever e damage to the tr ansmission and drive components can resul t. Chain t ension must be i nspected wit h the swing arm in the positi on shown in illus tration . Check the amount of chain sl ac[...]

123 MAINTENANCE Headlig ht Lamp Repl acement W ARNING: Due to t he nature of A TVs and where they are ridden, headl ight and tai llight lenses become di rty . Frequent washing i s necessary to mai ntain li ght- ing quali ty . Poor li ghting whi le ri ding can result in severe inj ury or deat h. CAUTION: Do not service whi le headli ght is hot . Ser[...]

124 MAINTENANCE Headlig ht Lamp Repl acement T rai l Blazer , Sport W ARNING: Due to t he nature of A TVs and where they are ridden, headl ight an d tailligh t lens es b ec om e dirty . F r equent washing i s necessary to mai ntain li ght- ing quali ty . Poor li ghting whi le ri ding can result in severe inj ury or deat h. CAUTION: Do not service w[...]

125 MAINTENANCE Headl igh t Lamp Repl acement Magnum 2x4, Ma gnum 4x4, T rail Bo ss 1. Remove the seat. 2. Remove the plastic panel surround- ing the upper port ion of the gas tank by fi rst rem oving the gas t ank cap. 3. Remove the Phi llips head scr ews on eit her si de of t he panel at the junc- tion of this panel, the lower panels, and the r e[...]

126 MAINTENANCE Headlig ht Adjust ment 10. Careful ly unplug the socket from the l amp. Remove the panel and set it asi de. 1 1. Replace the oil reservoir cap. 12. Stand the panel containi ng the headlight assem bly on end to allow access to the back of the headlight assembl y . 13. Disengage the wi re bail holding t he headli ght lamp in place and[...]

127 MAINTENANCE Headl igh t Lamp Repl acement Xpl orer 400, Xpl orer 500, Spo rtsman 500 1. Remove Phill ips screws from bottom of headlight pod at each front corner . NOTE: T o aid in accessing t hese screws, it may be helpful t o turn handlebar s to lef t or right and use a short, stubby screwdr iver . Removal of the front rack and cover may also[...]

128 MAINTENANCE Headlig ht Housin g Replacement 1. Rem ov e Ph illips sc rew s from bo ttom of headli ght pod at each fr ont corner . NOTE: T o aid in accessing t hese screws, it may be helpful t o turn handlebar s to lef t or right and use a short, stubby screwdr iver . Removal of the front rack and cover may also allow easier access. 2. Rem ov e [...]

129 MAINTENANCE T aillight/Brakelig ht Lamp Repl acement If t he tailli ght/br akelight does not work the lamp may need t o be replaced. 1. From the re ar o f the taillig ht re mo ve two screws holdi ng lens cover i n place and remove l ens cover . 2. Remove lamp and r eplace it wit h recom- mended lamp. 3. T est the tail light/ brakeli ght to see [...]

130 MAINTENANCE Cleanin g Y our A TV Keeping your A TV clean will not onl y improve i ts appearance but i t can also extend the lif e of various component s. Wit h a few precautions, your A TV can be cleaned much li ke an automobil e. W ashing If a high pressure t ype car wash system i s used, ext reme care must be taken t o avoid wat er damage to [...]

131 MAINTENANCE Storage (Cont.) 7. Drain t he recoil housing. 8. Block the A TV so all tires ar e sus- pended of f the gr ound. 9. Add Polaris Premium S torage Stab ilize r to the fue l tank . 10. Cover the A TV wit h a canvas cover . Do not use plast ic or coated mat erial s since they do not all ow ventilat ion of the ve- hicle. T ra nsporting Wh[...]

132 TROUBLESHOOTING Proce dures The foll owing inf ormati on is provi ded to help you ident ify pr obable causes for ques- tions you m ay have about the operat ion of your A TV . See your Polar is dealer wi th any addit ional questi ons you may have. ENGINE CRANKS BUT F AILS T O ST ART Stop Swit ch Of f No Fuel Wat er in Fuel Spark Plug Fuel V alve[...]

133 P AINT CODES Model Item Color Raw Mater ial No. PPG Ditzl er No. Springs Fire Re d 8520149 7060 1998 T r a i l B o s s Rims Bright W hite 8520153 2185 T r a i l B o s s Rack Fire Re d 8520149 72060 Springs Black 8520147 9440 1998 Magnum 2x4 Rim s Brushed A lu- minum N/A N/ A Rack Black 8520147 9440 1 9 9 8 Springs Fire Re d 8520149 72060 1 9 9 [...]

134 P AINT CODES Model Item Color Raw Mater ial No. PPG Ditzl er No. Springs Fire Re d 8520149 72060 1998 Xplorer 300 Rims Br ushed Aluminum N/ A N/A 1998 Springs Bur nished Brown 8520264 N/A 1 9 9 8 Xplorer 400 Rims Br ushed Aluminum N/ A N/A 1998 Springs Black 8520147 9440 1 9 9 8 Sport sman 500 Rims Black 8520147 9440 Springs Bonnie B lue 852014[...]

135 ACCESSORIES Trai l Blazer T rail Boss Sport Xpress 300 14 Gall on Sprayer N/A 2871087 N/A 2871087 Boom Mounti ng Kit N/A 2871340 N/A 2871340 42 ″ Spray Boom N/A 2871088 N/A 2871088 123 ″ Spray Boom N/A 2871089 N/A 2871089 Seeder/ Spreader , Elec. N/A 2871219 N/A 2871219 Speedometer 2871275 2871275 2871341 2761539 20mph Speedometer N/A N/A N[...]

136 ACCESSORIES Magnum 2x4 Scrambler 400 Scrambler 500 Xplorer 300 Xplorer 400 Xplorer 500 2871087 N/A N/A 2871087 2871087 2871087 2871340 N/A N/A 2871340 2871340 2871340 2871088 N/A N/A 2871088 2871088 2871088 2871089 N/A N/A 2871089 2871089 2871089 2871219 N/A N/A 2871219 2871219 2871219 STD TBA TBA 2871539 STD 2871789 2871085 N/A N/A N/ A 287135[...]

137 ACCESSORIES Trai l Blazer T rail Boss Sport Xpress 300 Gun Scabbard N/A 2870854 N/A 2870854 CV Protect or N/A N/A N/ A N/A Rack Bag, Large, Black N/A N/ A N/A 2871787 Rack Bag, Gray/Bl ack N/A N/A N/A 2871216 Rack Bag, Camo N/A N/A N/ A 2871506 Dual Headlight s 2871490 N/ A 2871490 STD K&N Air Filt er 2871509 2871509 2871508 2871509 Cover ,[...]

138 ACCESSORIES Magnum 2x4 Scrambler 400 Scrambler 500 Xplorer 300 Xplorer 400 Xplorer 500 2870854 N/A N/A 2870854 2870854 N/ A N/A 2871234 2871234 2871234 2871234 STD 2871787 N/A N/A 2871787 2871787 2871787 2871216 N/A N/A 2871216 2871216 2871216 2871506 N/A N/A 2871506 2871506 2871506 2870936 STD STD STD STD STD 2871508 2871508 2871786 2871509 28[...]

139 ACCESSORIES Trai l Blazer T rail Boss Sport Xpress 300 Rear Rack Kit 2871357 STD 2871357 STD Front Rack Extender 3.5 ″ N/ A 2871502 N/A 2871499 Front Rack Extender 8 ″ N/A N/ A N/A 2871318 Rear Rack Extender 3.5 ″ N/A 2871504 N/ A 2871501 Rear Rack Extender 8 ″ N/A 2870918 N/A 2871319 Gun Shovel Holder 2871315 2871315 2871315 2761427[...]

140 ACCESSORIES Magnum 2x4 Scrambler 400 Scrambler 500 Xplorer 300 Xplorer 400 Xplorer 500 STD 2871357 2871357 STD STD STD 2871502 N/A N/A 2871499 2871499 2871499 2870931 N/A N/A 2871318 2871318 2871318 2871503 N/A N/A 2871501 2871501 2871501 2870942 N/A N/A 2871319 2871319 2871319 2871315 2871315 2871315 2871427 2871427 2871427[...]

141 ACCESSORIES Magnum 4x4 Sport sman 500 14 Gall on Sprayer 2871087 2871087 Boom Mounti ng Kit 2871340 2871340 42 ″ Spray Boom 2871088 2871088 123 ″ Spray Boom 2871089 2871089 Seeder/ Spreader , Elec. 2871219 2871219 Speedometer STD STD 20mph Speedometer 2871085 2871353 Speedometer Pr otector 2871316 N/A Elect. Accessor y Brd. 2871802 N/A Gas [...]

142 ACCESSORIES Magnum 4x4 Sport sman 500 Rear Rack Kit STD STD Front Rack Extender (3.5 ″ ) 2871502 2871499 Gun Scabbard 2870854 2870854 CV Protect or 2871234 STD Rack Bag, Large, Black 2871787 2871787 Rack Bag, Gray/Bl ack 2871216 2871216 Rack Bag, Camo 2871506 2871506 Dual Headlight s STD STD K&N Air Filt er 2871508 2871786 Cover , Red/Blu[...]

143 ACCESSORIES Magnum 4x4 Sport sman 500 Accessory Wi nch Kit 2871461 2871461 Front Rack Kit STD STD Front Rack Extender 8 ″ 2870931 2871318 Rear Rack Extender 3.5 ″ 2871503 STD Rear Rack Extender 8 ″ 2870942 2871319 Gun Shovel Holder 2871315 2871427[...]

144 W ARRANTY LIM IT ED WARRANTY Polar is Industr ies Inc. , 1225 Hi ghway 169 Nor th, Mi nneapolis, Mi nnesota 55441- - 5078, gives a SIX MONTH LI MITED W ARRANTY on all components of the Polar is All T errai n V ehicle ( A TV) agai nst def ects in materi al or workmanship. Polar- is also gi ves a one year li mited war ranty on t he fi nal dri ve [...]

145 W ARRANTY This war ranty does not cover t he use of unauthori zed lubri cants, chemical s, or fuel s that are not compat ible wit h the A TV . The exclusive rem edy for breach of this warr anty shall be, at Polari s’ exclusive opti on, repair or r eplacement of any defec- tive mat erials, or component s or products. THE REMEDI ES SET FORTH IN[...]

INDEX 146 Engine Cooling Sy s tem 45- 47 .......... Acc es sories 135- 143 ................. Air Box D rain 98 ..................... Air Cleaner 95-101 .................. Air Filter Ser vic e, Magnum 97 ......... Air Filter Serv ice, Sport, Sc rambler 400 99 .......... Air Filter, Trail Blazer 100 ............. Air Filter, Scramblert 500 101 ......[...]

INDEX 147 Throttle Lev er 38 .................... Tire Inspec tion 1 19 ................... T oe Alignment 104 ................... T ool Kit 78 .......................... T orque Spec ifications 90 .............. Trail Obstac les 70 ................... Transmiss ion G ear Selec tor Operation 42 ................... Transmiss ion Lubric ation 1 15 ..[...]